Kawasaki C14 Concours / 1400GTR Valve Clearance Research & Resources

 

Research

Concours 14 parts: https://www.kawasaki.com/en-us/owner-center/parts/2010/ZG1400CAF

Fuel tank sits on the frame:

Cylinder cover parts and diagram. Isn't that fantastically complicated?

The battery box slots into the side of the frame. Not sure if I have to remove it to get to the cylinder head. Honestly, with that much frame around it, how on earth do you get into the valve cover at all?

Airbox diagram: it slots into the frame on the other side from the battery. Again, not sure if that all has to come out.

Based on what I'm seeing here I need to take a lot of photos as I dismantle and keep everything on a clean sheet in order next to the bike so I have a chance of getting it all back together again. Organization will be key!

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Hints at problems with sealing the new gasket? https://forum.concours.org/index.php?threads/valve-cover-gasket.53892/

Murph's Kits parts: https://murphskits.com/c14-valve-adjustment-kit-1/ promises to provide all the bits you need (that the dealer parts counter guy won't bother to tell you about):

Oil leaks become an issue unless you replace all the o-rings as well as including a new gasket? Might as well change the spark plugs and fuel filter while in there.  Ends up being $338 (CAD) for all of it, plus another forty bucks in shipping - still much cheaper than parts from the local dealer and with helpful additions so I'm not left with a leaky mess. I've got Murph's Kit bits all over the C14 and trust them. The set is ordered.

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Good list of parts numbers for C14: https://zggtr.org/index.php?topic=1650.0

2010 C14 Service manual - 99924-1431-01

AIR FILTERS
Air Filter Element - 11013-0014
BMC Air Filter - 466/04
K&N Air Filter - KA-1406

Fuel
Fuel Pump filter/strainer/whatever 49019-0013. From a 2013 Kawasaki 750 side-by-side (not sure what they are calling it).
Fuel Pump O-ring - 670E5075
Fuel pump (fuel pump housing would need to be disassembled) http://www.fuelpumpfactory.com/Kawasaki-fuel-pump-Concours-14-s/6323.htm

WASHERS & Push Rivets
Final Drive Crush Washer - 92022-1086
Final Drive O-Ring for Filler Cap - 92025-1735
Oil Drain Plug Crush Washer - 92065-097
Water pump coolant drain crush washer - 92200-0498 Adept Power Sports

Fairing screw nylon washers:
5.3mm ID X 11.5mm OD X .5mm thick - 92200-0006
10.4mm ID X 19mm OD X .5mm thick - 92200-0157

Windshield mounting screw nylon washers:
10.3mm ID X 17mm OD X 1.0mm thick - 92200-0380
Nylon Push Rivet (two sizes) - 92039-0051 & 99039-0051
Push rivet under the windscreen - 92039-0048
Motosport.com Bolt Brand 6mm Nylon Push Rivet - 2005-6RIV (These may not work)
Balkamp part number 665-1446 (pkg of 9) available at NAPA for (rivet 92039-0051)
Hillman push-in Nylon Rivet - 1/4 inch H#881216 (Lowes) barcode 0823671607, for the top of dash
Grainger http://www.grainger.com/Grainger/Push-In-Rivet-5MUF8 (not sure if these fit)
Amazon http://www.amazon.com/Tusk-Kawasaki-Suzuki-Fender-Rivets/dp/B0039LEU0I (not sure if these fit)


MC OIL FILTERS Designed for the bike
Kawasaki 16097-0004
K&N KN-303
Mobil1 M1MC-134 (crosses to a K&N KN-303)
Hiflofiltro HF303/303C
Amsoil EaOM103
Emgo 10-82222
Fram PH6017A
Parts Unlimited 010035X

Oil Filters others use (other than OEM fitment - use at own risk)
A/C Delco - PF2135
Amsoil - 24942 (I think this is a Wix filter)
Napa Gold - 1358
Napa - PS1358 (black and costs less)
Purolator ML16817 (made for MC, not sure if it fits our bikes)
Purolator Pure One - PL14610 (Note: The Purolator website does not recommend using cage filters on MCs)
Purolator Pure One - 2.5"- PL14612 (Note: The Purolator website does not recommend using cage filters on MCs)
Wix - short: 51358; long: 51356
Champion 7317 (same as SuperTech)
Mobil 1 M1-110

BULBS
Tail License Plate Bulb - 92069-1055, 5007, R5W (5 watt)
Front/ Rear Turn Signal Bulbs - 92069-1125
Turn signal bulbs are 7507A bulbs (BAU15s base)
Headlight Bulb 12V-60/55W - 92069-1002 (standard H4)
Small headlight Bulb 12V/5W - 92069-1016
City lights are either a 2825 (5w) or a 2886 (6w)
City lights (LED, inverted cone, white) 194 or 168

Switches
SPST Waterproof Miniature Rocker Switch (On-Off) 16A Green 12V (also available in red) .921" Long x .685" Wide x .551" Deep Part Number: NTE-54-204W $5.40 each https://shop.vetcosurplus.com/

TIRES/Wheels
Front Tire Size - 120/70ZR17
Rear Tire Size - 190/50ZR17
Front bearing seal (08/09) 92049-0050
Rear bearing seal (08/09) 92049-1061
Wheel Bearings (F) - 6005UU oem, or 6005 2RS1 or 6005 2RSH (SKF replacement numbers)
Wheel Bearings (R) - 6304UUC3 oem, or 6304 2RS1 or 6304 2RSH (SKF replacement) the "C3" designation is a standard for precision, SKF bearings are normally C3 unless specified otherwise...
Rear Wheel Bearing All Balls - 25-1353 (Comes with one seal - you need one kit - it has two bearings)
90 Degree retrofit valve stems for the original tire sensors: Honda part VALVE ASSY., RIM 42755-MCA-R31 2014 Goldwing

Steering
Steering Stem Bearings - All Balls Racing -Tapered roller bearing and seal kit for steering stem (steering head) C-14
Part No. 22-1039 Cost: $47.95 http://www.allballsracing.com/

BRAKE STUFF
Front pad Assembly - 43082-0071 (2 EA) (08-09)
Front pad Assembly - 43082-0112 (2 EA) (2010)
Rear pad Assembly - 43082-0055 (1 EA)
Rear brake pads - EBC FA254 (Kevlar) or FA254HH (Sintered)
Front brake pads - EBC FA417/4HH (Sintered)
Front pads - Ferodo FDB2220ST (mcstuff.com p/n 454-1071, requires two sets)
Rear pads - Ferodo FDB2111P (p/n 454-2682) (evidence is these don't last as long or bite as well as other brands)
Carbone Lorraine - 1177SBK5 (front x 2), 2813RX rear
Front ABS brake line - Galfer SS FK003D625-3
Caliper rebuild kits - https://brakecrafters.com/product/caliper-seal-kit-bcnr0036/

Engine Parts
Spark Plugs - CR9EIA replaced by CR9EIA-9, gap .036 IRIDIUM!
Valve cover gasket - 11061-0263
Pulsing Cover gasket - 92055-0086
Oil pan drain bolt - 92066-0079
Oil pan drain bolt with magnet - MP-01, MP-11 for the rear drive http://www.magneticdrainplug.com
Manual Cam Chain Tensioner APE KTZx14
(NOTE: This replaces the self adjusting cam chain tensioner and eliminates the 'startup rattle'. Downside is that you will have to keep an ear out on the adjustment. There is no track record on how long the adjustment holds. USE THIS AT YOUR OWN RISK! )

Replacement Exhaust Header Nuts - McMaster-Carr 93795A230 M8.0 Oval Locknut. Use with stainless steel washers.
Fuji-lok nuts for the Exhaust Header - Use with stainless washers
Note: the '10 manual specs 13ft/lbs for torque. This should apply to the other manuals as well.
Oil filler cap - 16115-1009 (note: Fits the rear drive as well)

Tools
Oil filter wrench - 57001-1249
Pennzoil oil filter wrench 2"-3 3/4" 51mm to 95mm
JIS +2 Driver (for the 'flies) http://www.ikaswebshop.com/hodjis2dr12s.html
15mm drag link tool for rear drive filler plug http://search.harborfreight.com/cpisearch/web/search.do?keyword=drag+link
Stem nut socket from CycleDude
Steering stem top nut - 12mm hex 79.7ft lbs torque
Front wheel removal - 13/16" spark plug socket, reversed
Rear Axle - 27mm socket for the large nut, 14mm hex wrench for the left side

Final Drive
Filler cap o-ring - 92055-049 (31mm)

Swing arm
OEM Left hand side torque arm bolt is 10x63mm with part number 92153B (used to be 92153A)
OEM Right hand side torque arm bolt is 10x67mm with part number 92153C (used to be 92153A)
The flanged lock nut part number is the same for both bolts 10mm diameter nut with part number 92210B

Electrical
Battery for FOBs - CR2025 3v (watch battery)
Battery for TPS - CR2032L/F1N http://www.digikey.com/product-search/en?x=0&y=0&lang=en&site=us&KeyWords=P668-ND
Other sources for TPS batteries https://octopart.com/cr-2032%2Fvcn-panasonic-19088802
Or P660-ND check both of them out on digikey's site.

12V bike battery sources
Stock battery FTZ14-BS Furakawa - dealer sourced most likely (expensive)
AGM MBTX12U 14AH by MotoBatt (I have this and it's working fine, no issues)
Shorai battery LFX21A6-BS12 Tender SHO-BMS01
Battery Stuff http://www.batterystuff.com/powersports-batteries/sYTX14-BS.html

Bodywork
Left side cowling parts 39156-031, 033, 034, 0371, 0395
Battery cover stud rubber grommet - Frame fittings, p/n 92075-1011, damper

Levers
Brake - ASV BRC511
Clutch - ASV BRC511

Key Blanks
Key Blank - ILCO KW14R Warning, this may only work for the 08 model locks and there appears to be two types of keys in use. The KW14R only works with one of them. If your key starts with an A it will be a "Silca KW14R" keyblank. If it starts with a B it will be an "Silca KW14" keyblank.
Works ok on the bags but you will need to not insert it the whole way for the seat as it doesn't have the stop the Kawi key does. http://www.mysecuritypro.com/index.asp?PageAction=VIEWPROD&ProdID=663
Ron Ayers has new Oven Knob keys. A and B style key. If you look at your key in the fob it will have a number that starts with either A or B.
27008-0050 Style A
27008-0051 Style B

TPMS sensor part numbers
US bikes 315 Mhz (green). Note that EUR, AU, SEA use 434Mhz sensors (blue). MY (have no clue what MY stands for) sensors 315Mhz (red)
2008-2013 21176-0125
2014-2015 21176-0748

Concours Tip Over

 No pride here at TMD. The other weekend I went out for a ride with my lovely wife and we stopped for a snack. The parking lot wasn't even but the bike was full of fuel and had the top box on and it was a very windy day. I had to lean on it to get it to stand up and thought it would be ok - you might see where this is going.

I was once told that bikes fall over, it happens to everyone, but I've never had it happen before. I'll be more cautious next time. My best guess is the road behind the restaurant channeled the wind making for even stronger gusts and it toppled the bike. We were around the corner on the patio when I heard the worst kind of smashing sound and immediately got up to come around to see Big Blue on its side. I remembered the lift with your legs holding the handlebar in and the back of the seat, and got the big thing upright again.

It started right up and I rode it around the corner to another spot on more even ground out of the wind tunnel. Much swearing ensued but it was really my own fault. I checked it twice to make sure it was stable, but that second check should have told me I didn't like how it was sitting and I needed to find a better spot. Lesson learned.

The wing mirrors on GTR1400 / Concours 14s are (big) plastic pieces over an aluminum frame. They're one of my least favourite stylistic choices on the bike. They work well but they are enormous and make what is already a big bike look even bigger, so my first reflex was to find a lower profile alternative. The bike looks much more svelte when it's mirrorless.

The only aftermarket option I could find is pretty much the same thing - industrially big. I might be tempted to customize something, like perhaps an electronic rear view option, but something stopped me. I've worked hard to get the C14 to fit, but it never has. Bar risers, modified foot pegs and a pang Corbin saddle and it still feels like it was made for someone else. Love the engine and it handles well enough with the rear tire mod (slightly larger profile balances the bike forward a bit more) and getting the suspension set for my size helped too, but it still feels like someone else's bike, so I started looking at other options.

I reached out to the metal shop teacher at my school but he can't weld aluminum. He suggested Fergus Welding & Machine Shop just up the river from us. It was described as 'turn of the century - 18th Century'. I gave them a telephone call (because they have no digital presence at all) and went over to show them my broken mirror frame.

Our shop teacher wasn't kidding. This place is in an old stone building and it was indeed old-school with paper filing upstairs and blacksmith come metal shop downstairs. The broken bit was in fact aluminum and their Yoda-like welder said that if it was 'white metal' he wouldn't be able to do anything with it and that he'd only find that out when he 'hit it' for the first time. I left my phone number on the box and off I went.

I got the bike undressed and cleaned everything up. I'm amazed at how strong the fairings are on this thing. Even with seven hundred odd pounds coming down on it the thing held up with only scratches.

Fergus Welding & Machine Shop called back end of the next day and Dave said he was able to sort it out. It cost me $25 and I tipped them with a six pack. The part was impossible to source used and a new metal piece was asking $260US, so I came out ahead there.

The job was really well done. Dave tacked the part back together following the break and then filled it like the magician he was described as. When I put the assembly back together it fit like a glove - all the holes lined up perfectly and when I took it out for a spin tonight everything is tight and works as it should. It gives you an indication of how over-engineered this bike is that it can tip over, break the metal mirror frame but not smash the mirror itself. There's a lot to like about a C14, but me fitting on it comfortably isn't one of those things.

Undressing the whole bike gave me a chance to clean it up properly. The owner before me parked it in a shed for several years and spiders made it their home. Many webby nests were found throughout, but they're all gone now. It also gave me a chance to lubricate the throttle cables and clean all the electrical connections of which there are many. This bike continues to amaze with how complicated it is, but it's build like a nuclear submarine.

Next steps? Sort out the fairings. If it were a more popular bike I could get some Chinese knock-offs and get them painted for a grand, but I'm not that lucky. I looked up Color Rite who I got the Neptune Blue touch up paint from when I first got the bike. The previous owner had it tip over on him (on the other side) and the touch up made it all but disappear.

Color Rite does good stuff, but it ain't cheap and their shipping (at nearly $100CAN!) is astonishing. If I'm $200 in to touch up, perhaps I can remove the panels, flat them myself and then find a local paint shop to do them up for me. I'll have to see what that costs.

Some Concours 14 Mirror Links:

https://www.aliexpress.com/item/1005005337788259.html

https://forum.concours.org/index.php?threads/mirror-replacement.13139/

Ebay Links are enormous

The electronic option: https://youtu.be/UZ2XPHB7mo4

https://innovative-cycles.com/gps-video-mirrors

https://www.aliexpress.com/w/wholesale-motorcycle-wing-mirrors.html

Full Fairing Bolt Kit.

Dodgy fairing options don't include second generation Concours 14/GTR1400s.

Lots of 8s

 

I've been on the road for work for the past couple of weeks (Newfoundland is spectacular!) The weather from there followed us back and we haven't seen the sun for many days, until this weekend! It finally broke and I've gotten some riding in.

I was hoping to get the old Tiger to 100k this year in its 20th year on the road. On the way to that I managed to hit eighty-eight thousand, eight hundred and eighty-eight kilometres! Very satisfying, and the bike looked great doing it:

I pushed my luck the next day and took Connie out for a couple of hours to Hockley Valley and back...

Weather's been good this week too, maybe we're finally into spring time! I had the C14 out again for a ride over to the Forks of the Credit after work today... time to make some miles!